DE102013205574B4 - HANDLING LARGE FORMAT CELLS FOR QUICK ASSEMBLY - Google Patents

Abstract

A method of assembling battery pack components, the method comprising: combining a substantially planar battery cell (100) and a substantially planar cooling fin (102) such that face-to-face contact is made therebetween; the cell and fin combination of one Orientation in which the facing adjacent contact lies in a substantially horizontal plane is conveyed to an orientation in which the facing adjacent contact lies in a substantially vertical plane; a plurality of the substantially vertical cell and rib combinations between a plurality of End plates (104) are aligned along an axis substantially normal to a planar dimension defined by the facing adjacent contact to thereby define a stack; the stack is compressed along the substantially normal axis; at least a portion of the stack into a r load-bearing structure is enclosed; andconnecting the stack to an electrical circuit thereby forming an assembled module, wherein conveying comprises: a first plurality of the substantially vertical cell and fin combinations oriented with electrical tabs in a first position along a conveying a first conveyor (1110A); conveying a second plurality of said substantially vertical cell and rib combination oriented with electrical tabs in a second position along a second conveyor (1110B); and at least one substantially fixed guide (1140) is used to alternately intermix the first and second plurality of substantially vertical cell and rib combinations.

Description

BACKGROUND OF THE INVENTION

This invention relates generally to a way of improving the manufacture of individual battery cells into assembled modules and, more particularly, to the assembly of such battery modules in a continuous process.

The increasing need to improve vehicle fuel economy and reduce vehicle emissions has led to the development of both hybrid vehicles and all-electric vehicles. All-electric vehicles can run from one set of batteries (made up of many smaller modules or cells), while hybrid vehicles can run two or more energy sources such as A gasoline engine (also referred to as an internal combustion engine) which is used either as an aid to or in conjunction with a battery pack. Two popular versions of hybrid vehicles are currently in use. In a first version (known as a charge-consuming hybrid architecture) the battery can be powered from a conventional power grid such as B. a 120 V AC or 240 V AC line can be charged. In a second version (known as a charge sustaining hybrid architecture) the battery receives all of its electrical charge from either or both of the internal combustion engine and regenerative braking. In one form of each version, the set consists of many modules, which in turn are made up of many individual cells.

Typically, the individual cells that make up a module have a generally planar (or prismatic) structure that includes alternating stacks of plate-like positive and negative electrodes having a similarly shaped electrolytic separator positioned between each positive and negative electrode pair; these separators are used to prevent physical contact between the positive electrodes and the negative electrodes within each cell while allowing ion transport between them. In one form, the separators are designed to absorb the cell's liquid electrolyte. Cooling features are also often used to carry away the heat generated by the various individual cells during charging and discharging activities associated with battery operation; in one form, such cooling features can be formed from yet another generally planar, plate-like device that can be added between the various cells as part of the stacked arrangement of components that make up the module. Connection tabs extend from a peripheral edge of each cell to allow a mechanical and electrical connection between the electrodes of the individual battery cells. In general, correct alignment of the various contact lugs is necessary to ensure low electrical resistance to busbars or similar conductors, as well as for robust mechanical connectivity. These prism-shaped cells usually have a soft, flexible housing (called “bag cells”) or a hard housing (called “can cells”). Depending on the application, the individual battery cells can be arranged in series, parallel, or combinations thereof to produce the desired voltage and capacity. Various frames, battery trays, covers, and similar structures may be included to provide support for the various cells, modules, and sets and, as such, to help define a larger array of such cells, modules, or sets.

Current general practice for handling cells during assembly is to use self-contained carriers. It is known to manufacture a battery module assembly in a mold using a robotic “pick and place” system. Such approaches remove the cells from the shipping packaging, transport the cell via a conveyor to a first process step (typically in the form of electrical verification) and then transport them to the high-precision carrier via the receptacle and tray. Such approaches are useful for the assembly of layered cells with tight placement tolerance requirements as well as those with special handling requirements. While this method is effective in protecting the cell during the assembly operation, it also results in costly tooling and wasted assembly time to position the carrier, remove the part for the specific station operation, and then return the part to the carrier for move it to the next step. This in turn brings with it the necessity that the packaging and tooling work steps become more complex and expensive.

Out DE 10 2011 106 690 A1 Battery packs are known in which a substantially planar battery cell is combined with a substantially planar cooling fin, and a plurality of cell and fin combinations are stacked between end plates.

In US 2006/0 255 533 A1 a machine for stacking battery plates is described. The individual panels are stacked in a stack via conveyor belts, with the panels from one horizontal orientation can be converted into a vertical orientation.

Further methods and devices for stacking battery plates are disclosed in US Pat U.S. 4,824,307 A , DE 36 22 169 A1 and U.S. 5,820,335 A disclosed.

It is the object of the invention to provide an improved method for assembling battery pack components and a corresponding system which have a high operating speed.

The solution is provided by a method with the features of claim 1 and a system with the features of claim 5.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method for assembling battery pack components into a battery module arrangement is disclosed. The method includes combining a substantially planar battery cell and a substantially planar cooling fin so that they are in contact with one another along a common surface. From this, the cell and rib combination is reoriented so that this facing adjacent contact goes from being in a substantially horizontal plane on the conveyor mechanism to being in a vertical plane, after which many of the now vertically oriented combinations between end plates along a Are aligned longitudinal axis, which is formed by the conveyor mechanism. Once this alignment is complete, the stack formed from the multiple aligned cell and rib combinations and end plates is compressed along the axis which is substantially normal to the planar interface between the cells and the ribs; this essentially normal lies preferably in the same longitudinal axis which is formed by the conveying mechanism. Once the cells and associated components (such as cooling fins, end plates, or the like) making up the stack have been properly compressed, at least a portion of the stack is enclosed within a suitable supporting structure and then connected to one or more electrical circuit components to form an assembled module. The system used for conveying and stacking forms an integrated whole which is formed from a fixed, camed structure (also referred to herein as a cam), rollers, hoists and a conveyor belt. When a belt or similar generally flat conveyor surface moves, the cam profile changes the cell orientation for the next work step. The advantages of the system of the present invention include lower cost, faster assembly of battery modules and battery packs by eliminating the need for high precision packaging and tooling. Furthermore, the system favors reduced individual part costs by allowing a larger dimensional deviation than a conventional “pick and place” system.

According to another aspect of the present invention, a method of stacking individual cells of a larger battery module or battery pack is disclosed. The method includes combining first and second substantially planar battery cells and respective first and second substantially planar cooling ribs such that face-to-face contact is made therebetween. The positive and negative tabs that extend from the edges of the cells of the first combination of cells and ribs form a tab pair that define a first tab orientation, while those that extend from the edges of the cells of the second combination of cells and ribs , form a tab pair that defines a second tab orientation. The two cell and rib combinations are conveyed in a manner to change that from a substantially horizontal plane to a substantially vertical plane; once in the generally vertical orientation, they are placed in an alternating (i.e., spaced apart) arrangement along the conveyor mechanism (in addition to end plates if necessary). From here they can be stacked on a discharge carrier or similar pickup tool or platform for compression or other subsequent steps.

In accordance with yet another aspect of the present invention, a system for assembling a battery module is disclosed. The system comprises a conveyor device which is formed from at least two conveyor belts, so that a first combination of cells and ribs (with a specific orientation of the positive to the negative contact lugs) is conveyed along a first of the conveyor belts, while a second combination of cells and ribs, which defines another specific orientation of the positive to the negative contact lugs, is conveyed along a second of the conveyor belts. A variety of lifters can help adjust the orientation of one or more of the cell and rib combinations along each of the first and second conveyor belts; these lifting devices are moved along a substantially vertical direction by the action of one or more cams, so that openings or similar empty spaces in the conveyor belts allow the lifting devices Press against an edge (preferably, but not necessarily, the leading edge) of the contact to change the orientation of the cell and rib combination. A substantially fixed guide cooperates with one or more conveyor belts to promote an alternately aligned arrangement of the first and second cell and rib combinations (which are in their substantially vertical orientation) into a stack. Additional devices for picking up and compressing the stack are also included as part of the system, as well as a device for placing a supporting structure on the stack while the stack is in its compressed state, while also including a device for securing at least one electrical component is included on the supported stack. In another form, the conveyors, cams, lifts and guides are configured as a stacking system for use in providing the alternating orientation of the first and second cell / fin combinations (along with the corresponding end plates and auxiliary structures) into the desired stacked relationship.

Figure list

• 1 ein fiktives Fahrzeugantriebssystem in der Form eines Batteriesatzes zeigt;
• 2 in getrennter Form verschiedene Batteriekomponenten zeigt, die in dem Batteriesatz von 1 verwendet werden;
• 3 einen Verfahrensfluss zeigt, der verwendet wird, um ein Batteriemodul gemäß einem Aspekt der vorliegenden Erfindung zu produzieren;
• 4 einen ersten Abschnitt des Stapelarbeitsschritts von 3 zeigt;
• 5 einen zweiten Abschnitt des Stapelarbeitsschritts von 3 zeigt; und
• 6 das Entfernen der Komponenten von der Förderlinie zum Beenden des Modulstapel-Arbeitsschritts zeigt.

The following detailed description of specific embodiments is best understood by reading in conjunction with the following drawings, in which like structures are designated by like reference numerals and in which:

• 1 Figure 3 shows a fictional vehicle propulsion system in the form of a battery pack;
• 2 shows in separate form various battery components included in the battery pack of FIG 1 be used;
• 3 Figure 10 shows a process flow used to produce a battery module in accordance with an aspect of the present invention;
• 4th a first portion of the batch operation of 3 shows;
• 5 a second portion of the batch operation of 3 shows; and
• 6th shows the removal of the components from the conveyor line to complete the module stacking operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the beginning 1 is a battery pack 1, the multiple battery modules 10 with cells 100 used, shown in partial exploded view. Depending on the desired power output, many battery modules 10 can be combined into larger groups or subsections; these can be aligned in order to be supported by a common battery tray 2, which can also serve as a support for coolant hoses 3, if supplementary cooling is desired if necessary. In the present context, the terms “battery cell”, “battery module” and “battery pack” (as well as their abbreviations “cell”, “module” and “pack”) are used to refer to different levels of components of an overall battery-based power system as well as theirs Describe assembly. For example, many individual battery cells can form the building blocks of battery modules. Many battery modules (in connection with additional devices) in turn form the finished battery set.

A transverse plate 4 can define a primary load-bearing structure which acts as an interface for the coolant hoses 3 as well as can include a battery disconnect unit in the event that battery maintenance is required. In addition to providing support for the many battery modules 10, the battery tray 2 and the transverse plate 4 can contain other modules such as e.g. B. support a voltage, current and temperature measuring module 5. Arranging individual battery cells 100 (which is described in greater detail below) within one of the battery modules 10 is also shown, as is the covering thereof by a voltage and temperature submodule 6 in the form of plug connections, busbars, fuses or the like.

Although shown fictitiously in a T-shaped configuration, those skilled in the art will appreciate that the battery pack 1 can also be configured into other suitable configurations. Likewise, the battery set 1 can - in exemplary configurations - between approximately two hundred and three hundred individual battery cells 100 include, albeit (like the arrangement) the number of cells 100 can be larger or smaller depending on the power requirement of the vehicle. In an exemplary form, the battery pack 1 is formed from three sections, a first of which is made up of two modules 10 with thirty-six cells 100 is formed in each module 10 to provide a section of seventy-two cells disposed along the vehicle longitudinal axis of the T-shaped battery pack, a second of which is comprised of two modules 10 having thirty-six cells 100 in each module 10 and an eighteen cell module 100 is formed to provide a section of ninety cells (also arranged along the vehicle longitudinal axis), and a third (arranged on the vehicle transverse axis of the T-shaped battery pack 1) of three modules 10 with thirty-six cells 100 in each module 10 and an eighteen cell module 100 is formed to be a portion of one hundred and twenty-six cells for a total of two hundred and eighty-eight such cells. Other features such as B. a maintenance disconnect device 7, an insulation 8 and a cover 9 complete the battery pack 1. Besides the aforementioned battery disconnect unit, other electronic power components (not shown) including a battery management system or similar control devices can be used.

Referring next to 2 An embodiment of a section (also referred to herein as sub-group 110) of a battery module 10 is shown in an exploded view. To form the module 10, at least some of the components discussed below may be made up of multiple cells in a repeating, stacking fashion 100 formed subgroup 110 are arranged. An end frame (also referred to as an end plate) 104 and a repeat frame 106 form the basis for the structure of the subassembly, wherein each repeat frame 106 can serve to provide a secure mounting position for a corresponding cell 100 to provide. Furthermore, cooling fins (or plates) 102 carrying a liquid can be in thermal communication with the battery cells 100 be arranged as a way to further increase the heat absorption capacity and subsequent heat transfer; their proximity to one of the repeat frames 106 enables a convenient attachment site in a manner generally that of the cells 100 is similar. The end frames 104 and the repeat frames 106 are typically made of a lightweight, non-conductive material such as plastic. A plastic (e.g., polypropylene, nylon 6-6) and other inexpensive materials, and can be fiber reinforced for structural strength if desired. In an optional form, an insulating plate 108 can be placed between the battery cell 100 and the cooling fin 102 or the frame 104 , 106 placed around the battery cell 100 to protect. In a preferred form, the insulating plate 108 is made of a plastic or a similar material and can be attached to the cooling fin 102 to be appropriate.

In particular, define the many individual battery cells 100 a generally prismatic structure made up of an anode and a cathode separated by an electrolytic membrane (details not shown). In a preferred form, the cells are 100 made from a lithium ion compound or similar composition as known to those skilled in the art to provide an electrochemical reaction. Positive and negative connection tabs extend outwardly from a peripheral edge of the respective anode and cathode to provide electrical connectivity with other battery cells. The contact tabs are preferably formed from materials based on aluminum (positive contact tab) and based on copper (negative contact tab), and are often not of the same type. Joining processes such as B. using z. B. different forms of welding can be used to form the necessary mechanical and electrical connection between the contact lugs. Likewise, define the associated structure of the frame 104 , 106 the cooling plates 102 and insulating plate 108 (when at least one of the last three is present) is of similar generally prismatic configuration and is typically disposed between adjacent cells in a stacked arrangement as shown. In one form the end frame 104 in the form of a plate that acts as an containment structure for the assembled stack of individual cells 100 serves. In a planned embodiment, a stacked module 10 consists of two end panels 104 , thirteen cooling plates 102 and twelve prism-shaped can cells for a total of twenty-seven parts.

Referring next to the 3 to 6th Shown is a method 1000 of fabricating multiple battery subassemblies 110 into various modules 10 with a highly productive assembly line in accordance with an aspect of the present invention. While the subassemblies 110 depicted herein are shown using a can cell construction, those skilled in the art will appreciate that they can be applied to pouch cell designs as well. Significantly, the assembly line 1100 forms a single line (rather than multiple lines) for assembly of the module 10. With specific reference to FIG 3 an overview of the main steps in the process is shown, first taking individual cells first 100 an open circuit voltage (OCV) test 1005 to determine their electrical suitability. In a shape are the cells 100 unloaded from a magazine (not shown) or similar carrier. As an example, the magazine may have many apertures defined therein to allow easy access by the inspector (not shown). Once it has been determined by the auditor that a single cell 100 is satisfactory, it is moved (e.g., by a pusher or similar device (not shown)) onto the assembly line 1100, at which point a cooling fin 102 can be added 1010 to put them in facing arrangement with the cell 100 to discard. There can be parallel activities with the endplate 104 and the cooling fins 102 take place (saves the need to do an OCV test on the endplate 104 to be carried out). Once all of the cells 100 , the cooling fins 102 and the associated components (such as the end plates 104 ) have been assembled, they move on to a batch work step 1015 , where she for the subsequent squeezing 1020 aligned along their longitudinal axis up to a predetermined force and displacement. Those skilled in the art will appreciate that the force and displacement for compression will be related to the cell chemistry and fin structure, with typical compression forces in the range of one hundred to four thousand Newtons and a compression displacement of one to thirty millimeters and then trapping within one suitable box-like structure 1025 during a framing and masking operation 1030 takes place. From here bus bars and similar electrical connections (which can be part of the aforementioned voltage and temperature sub-module 6) and a subsequent quality control and electrical tests 1040 executed.

With specific reference to 4th combined with 3 An edge elevational view of the assembly line (or tooling) system 1100 is shown, wherein a conveyor 1110 cooperates with a plurality of cams 1120 and wheeled lifters 1130 to change the stacking orientation of each of the individual cells 100 and cooling fins 102 combination, the is used in a battery module according to an aspect of the present invention. In a preferred (although not necessary) form, the cooling fin 102 a depth of about 10 millimeters while the cell 100 has a depth of about 12 millimeters. In the view shown, the conveyor 1110 (which in a particular embodiment is in belt form) moves the generally horizontally oriented cells 100 in a left-to-right direction to allow the profile of the cams 1120 to force the downwardly biased (e.g., gravity or spring loaded) elevator 1130 upward through openings formed along the conveyor 1100. This in turn causes the cells to grow 100 change from their horizontal orientation on the left to their substantially vertical orientation on the right in preparation for stacking. It is essential that the elevator 1130 spacing (which can be about 25 millimeters in one shape) and the cam 1120 profile are designed in such a way as to allow the cells 100 be oriented without causing substantial forces on the cells 100 who have favourited cooling fins 102 and additional components are applied or allowed to separate from one another; however, adjacent lifting devices 1130 (which are actually plate-shaped devices) are close enough to one another that as soon as the individual cells 100 / Ribs 102 combinations are moved into their vertical orientation, they do not stand free when they are between such adjacent lifting devices 1130.

Referring next to 5 combined with 3 Figure 3 is a view of the alignment and stacking 1015 of cells 100 from 4th shown from top to bottom. As noted above, the elevators 1130 are generally plate-like in shape that include a lateral dimension that extends across much of the width of the conveyor 1110. The stacking process is completed by removing the cells 100 coming from parallel conveyors 1110 through one or more guides 1140 that position and support the parts as the lifters 1130 are retracted are indexed. It is essential that the guides 1140 combine the two previously separate conveyor streams 1110A and 1110B to allow the parts to be processed in parallel and in the correct order on a single conveyor 1110. In one form, the fixed guides 1140 can be made of a hard plastic construction to promote high wear resistance. As for the use of two parallel conveyors running into one, a first conveyor 1110A can move the now vertical cells 100 Move so that the positive (ie, aluminum-based) tab 105A of an underlying cell 100A is in a conveyor 11 10A stream on a laterally outer portion of the combined conveyor 1110 while the negative (ie, copper-based) tab is 105B located on a laterally inner portion of the combined conveyor 1110. This first conveyor 1110A may correspond to a first tab position or orientation. The second conveying device 1110B is designed in exactly the opposite way, with in particular the contact lugs 105A and 105B of the cell 100B below being arranged in such a way that, as soon as the respective sub-groups containing the first and second cells 100A, 100B lie next to one another the positive tab 105A of one cell is adjacent to a negative tab 105B of the adjacent cell, as shown at location 1115. The second conveyor 1110B may correspond to a second tab position or orientation. The close cooperation of the guide 1140 and the elevator 1130, coupled with a suitably low coefficient of friction between them and the cells 100 helps to ensure a tight fit of the facing neighboring cells 100 as they move down the conveyor 1110 to await the compression. Those skilled in the art will appreciate that the choice of material, surface finish, and geometry of the guide 1140 will depend on the cell and Cooling fin materials, dimensions and their assembly speed will depend. As can be seen from the various changes in orientation that occur while influencing the cell 100 must take place the cell 100 and the additional components (such as cooling fins 102 , Separators or the like) must be sufficiently attached to one another that they do not separate from one another during such a change in orientation accompanying their movement along the assembly line 1100 formed by the conveyor 1110, the cams 1120, the lifting devices 1130 and the guide 1140. Furthermore, the surfaces of the cells must 100 which are in contact with the lifters 1130 must be rigid enough to maintain their shape when the parts change orientation. In addition, the cells must 100 Have self-positioning features to allow them to naturally nest with one another when they come together. In 4th has the cooling fin 102 Features on the corner on that with the cell 100 engaged, with which it is in a facing configuration, with about four millimeters of material and a recess on the back of about four millimeters to accommodate the next cell. These characteristics allow the cell 100 on a simple assembly line 1100 on the basis of a conveyor without the need for precision carriers and thereby reducing otherwise unnecessary assembly steps. In a special form there can be between about twelve and twenty-four cells 100 / Cooling fins 102 combinations between a pair of end plates 104 (one of which is shown moving along a second conveyor 1110B).

The use of an integrated approach between elevator 1130 and conveyor 1110 with cams 1120 and guides 1140 for cell 100 orientation and part sequencing facilitates quick assembly for subassemblies 110 and similar large format cells by positioning the parts for stacking, without the need to change directions as required with conventional pick-and-place equipment. Such a system as the one disclosed herein not only accurately handles parts that are loosely assembled and moving at high speeds (allowing for greater part dimensional variation), but allows for the parts that are being assembled to define an edgewise orientation that Use of small production areas. The assembly line system 1100 is easily adaptable to higher or lower speeds, either by adjusting the line speed or by adjusting the length of the system 1100. In contrast, a functionally equivalent approach using traditional pick and place systems or robots would require the use of complex rod ends and tooling to constrict the components. The present inventor estimates that a system 1100 based on the present invention would run approximately ten times faster than a pick-and-drop system or a robot-based system; which also takes up a much larger production floor space and requires much more capital investment in order to be suitable for large production volumes.

Referring next to 6th combined with 3 Figure 10 shows a top-down view of a group of aligned cells 100 which is then moved in a left-to-right motion along the conveyor 1110 at a higher speed rate than the conveyor onto a stationary holding tool 1150 which is in a form as a discharge carrier for receiving the alternately aligned cells 100 can be designed. As shown, there is a single end plate 104 from 2 disposed in a face-to-face adjacent relationship with the holding tool 1150. Additional guides 1145 with integrated brushes are located along the conveyor 1110 for continued alignment of the cells 100 ensure during their movement. When the cells 100 move into these guides 1145, the lifting devices 1130 are the 4th and 5 lowered and the cell 100 position and orientation are maintained by influencing the brushes. Then the group of cells 100 moved to the outlet carrier 1150 using a movement faster than the speed of the conveyor 1110. In this illustration, the movement is terminated by a mechanical arm 1160, which indexes into position in order to grasp the last cell group on the left and pull the cell groups to the right onto the discharge carrier 1150. As such, the outlet support 1150 is designed to support the cells 100 to maintain alignment, and has a fixed holding tool 1152 located along one axial end (currently shown as the right side) to hold the cells 100 and a moveable holding tool 1154 (currently shown as the axial end on the left) that can retract to allow the cells to move 100 both move onto the outlet carrier 1150 and be held in position during the transfer. Guides 1156 attached to the tool operate around the side edges of the various cells 100 of subgroup 110 to contain. In a preferred form, the surface of the outlet support 1150 defines a sufficiently low coefficient of friction to permit the edgewise sliding of the cells 100 across the surface to facilitate. How As shown, the spout support 1150 defines a box-like structure such that one or more of the fixed holding tool 1152 and the guides 1156 attached to the tool act as vertically upright members (i.e. walls) on different sides, so that the movable holding tool 1154 (the how its own upright structure acts) against one end of the stack the stack in the box-like structure formed by the discharge carrier 1150 is compressed. Once all cells 100 , which form the module 10, are appropriately aligned and placed on the outlet support 1150 as a subassembly 110, they are ready to accommodate the supporting structure, electrical interconnection and other arrangement, as explained in more detail below. In this present form, the subassembly 110 is considered to be a soft stack.

Then the soft pile becomes the batch work step 1015 one the squeeze work step 1020 subjected, wherein the outlet support 1150 (with the sub-group 110 is placed on edge and is axially enclosed by the fixed holding tool 1152 and the movable holding tool 1154 and laterally by the guides 1156 attached to the tool) is first rotated about a horizontal axis, so that the components of the subset to the reference point at the top of the cells 100 can be arranged. This rotary step is completed prior to compression to reduce the height difference from one cell to another, which helps promote the safe joining of the busbar (not shown) by laying the surfaces as close as possible prior to joining. Those skilled in the art will appreciate that the choice of engineering solutions for the rotating step may include tool-based solutions (not shown) or gentle compression (not shown) or similar means that prevent the components from separating. A compressive force of 180 ° around the axial dimension of the soft stack is then transmitted through the movable holding tool 1154 in the direction of the stationary holding tool 1152. This compression occurs up to a predetermined force and distance. Those skilled in the art will appreciate that the force and displacement for compression will be related to cell chemistry and fin design, with typical compression forces ranging from one hundred to four thousand newtons and a compression displacement of one to thirty millimeters. Once this predetermined level is reached, a box-like frame (not shown, but e.g. designed as a U-shaped structure with its own end plate with interlocking features) around the compacted stack (e.g., by means of laser, resistive or mechanical fastening), after which the compressive force is released so that the frame continues to hold the stack intact along the lateral edgewise dimension of the stack. From here, the unit is turned back 180 ° around the horizontal axis, after which barcode and similar scanning work steps can optionally take place. Finally, the frame cover (which includes wire harnesses, busbars, connectors and additional electronic devices, all of which may be contained in an integrated cell sensing board (ICSB)) is attached to the vertical stack and frame. These frame addition and cover addition steps are shown at 1030. From here the bus bars are made 1035 welded. In a preferred form, the steps 1030 and 1035 Executed in an automated (rather than manual) process as open high voltage contacts could endanger nearby workers, while cleanliness requirements would be equally easier to maintain. In an even more preferred form, the electrical connections (such as those in connection with the bus bars and other ICSB components) can be made in a bus bar joining station (not shown) where once the unit is securely housed therein , Setup and welding steps are carried out. The welding activities - which are preferably used to make electrical connections between the busbars and the contact tabs 105A, 105B extending from each cell 100 extending away to fix can be of any shape including ultrasonic welding or resistance welding or laser welding and can also be supplemented with mechanical fastening or the like.

After the welding 1035 When the busbars are finished, there will be a quality control (QC) step and an electrical step 1040 executed. It can e.g. B. Barcodes, which represent the serial number of the various module 10 components, are attached to allow later identification of certain components. Likewise, a check on the electrically connected devices such. B. voltage, temperature sensing module (VTSM, from English. Voltage, temperature sensing module) boards, a voltage, current and temperature sensing module (VITM, from English. Voltage, current and temperature module), a voltage, current and Control module (VICM, from English. Voltage, current and control module) as well as the aforementioned busbars and other exposed electrical contacts can be carried out. An additional check can also be made on the welds that have been used on the busbars or similar devices. Once the verification and similar QC checks have been performed, the finished module 10 can be moved (e.g., by a manual or automated guide car or conveyor) to other workstations on the production site for additional assembly steps. These steps may include assembling the modules 10 into larger package-like components; this can be the attachment of battery trays and cross plates (such as the battery tray 2 and the cross plate 4 of FIG 1 ), the installation of cooling fluid devices (e.g. the one in 1 shown hoses 3, pipes or the like) and a leak test (e.g. using an air mass flow or a similar liquid-free technique) and a pressure test of the same, the attachment of electrical busbars, fuses and the associated electrical cabling and control circuit as well as the Insulation 8 and the cover 9 on the battery tray 2 (also from 1 ), the electrical inspection of the various modules 10 within the battery pack 1, the connection of vehicle fasteners (such as a crossbar or similar bracket (not shown) to the upper battery pack 1, the application of suitable barcodes, stickers and similar component identification means, finally include quality control and relocation to a shipping rack or similar container and then on to the vehicle assembly plant for installation in a vehicle.

List of reference symbols

100

Zelle

102

Kühlrippe

104

Endplatte

1005

OCV

1010

Rippe hinzufügen

1015

Stapeln

1020

Zusammendrücken

1025

Schachtelrahmen

1030

Rahmen hinzufügen

1030

Rahmen anbringen

1030

Abdeckung hinzufügen

1035

Schweißen der Sammelschienen

1040

QC/Elektrisch

* Fertiges Modul

100

cell

102

Cooling fin

104

End plate

1005

OCV

1010

Add rib

1015

Pile

1020

Squeeze

1025

Box frame

1030

Add frame

1030

Attach the frame

1030

Add cover

1035

Welding the busbars

1040

QC / electrical

* Finished module

Claims (8)

A method of assembling battery pack components, the method comprising: a substantially planar battery cell (100) and a substantially planar cooling fin (102) are combined so that a facing adjacent contact is made therebetween; conveying the cell and rib combination from an orientation in which the facing adjacent contact lies in a substantially horizontal plane to an orientation in which the facing adjacent contact lies in a substantially vertical plane; aligning a plurality of the substantially vertical cell and rib combinations between a plurality of end plates (104) along an axis substantially normal to a planar dimension defined by the facing adjacent contact to thereby define a stack; compressing the stack along the substantially normal axis; at least a portion of the stack is enclosed in a supporting structure; and the stack is connected to an electrical circuit to form an assembled module, wherein the conveying comprises that: conveying a first plurality of the substantially vertical cell and fin combination oriented with electrical tabs in a first position along a first conveyor (1110A); conveying a second plurality of the substantially vertical cell and fin combination, oriented with electrical tabs in a second position, along a second conveyor (1110B); and at least one substantially fixed guide (1140) is used to alternately mix the first and second pluralities of the substantially vertical cell and rib combinations. Procedure according to Claim 1 wherein conveying the first and second plurality of substantially vertical cell and fin combinations comprises conveying them along a plurality of substantially parallel conveyor belts until at least contact between the guides (1140) and the first and second pluralities made of substantially vertical cell and rib combinations. Procedure according to Claim 2 , wherein the conveying is carried out on at least one conveyor belt. Procedure according to Claim 3 wherein a portion of the at least one conveyor belt used to move the cell and rib combinations from a substantially horizontal orientation to a substantially vertical orientation change, cooperating with a cam (1120) provided structure and a plurality of lifting devices (1130) spaced along a longitudinal dimension of the at least one conveyor belt and movable in response to the cam (1120) provided structure, so that a portion at least one of the plurality of elevators (1130) contacts the cell and rib combinations to effect a change in orientation thereof. A system for assembling a battery module from a plurality of individual battery cells (100), the system comprising: a conveyor (1110) having a plurality of conveyor belts such that a first combination of cells and ribs defining a first tab orientation is conveyed along a first of the conveyor belts and a second combination of cells and ribs defining a second tab orientation is conveyed along one the second of the conveyor belts is conveyed; a plurality of elevators (1130) configured to adjust the orientation of at least one battery cell (100) along each of the first and second conveyor belts; at least one cam (1120) which interacts with at least one of the conveyor belts and the plurality of lifting devices (1130), so that upon contact between at least one of the plurality of lifting devices (1130) and the at least one cam (1120) the at least one of the A plurality of elevators (1130) are in contact with a respective one of the first or second one of the cell and rib combinations to effect a change in orientation thereof; at least one substantially fixed guide (1140) cooperating with at least one of the first and second conveyor belts to promote an alternately aligned arrangement of the first and second cell and rib combinations into a stack, while the alternately aligned first and second cells - and rib combinations are in a substantially vertical orientation; means for receiving the stack from the conveyor (1110); a device for compressing the stack once the stack has been delivered to the device for pickup; means for placing a support frame on the stack while the stack is in its compressed state; and a device for attaching the at least one electrical component to the supported stack. System according to Claim 5 wherein the spacing between the plurality of elevators (1130) along a dimension of the conveyor (1110) is such that when placing at least one of the first and second cell and rib combinations in the substantially vertical orientation by an adjacent pair of the plurality of elevators (1130) any skewed deviation of the at least one of the first and second cell and rib combinations is at least substantially eliminated until the stack is formed on the device for receiving. System according to Claim 5 further comprising a mechanical arm (1160) configured to index a group of the alternately aligned first and second cell and rib combinations into position to grip an end of the group remote from the containment device and the Group to pull the pickup device. System according to Claim 7 , wherein the movement of the mechanical arm (1140) is faster than a feed rate that was given to the group by the conveyor (1110).

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